Kyocera KC40T, KC130TM INSTALLATION

INSTALLATION MANUAL

FOR THE

KC40T〜KC130TM

OF

SOLAR PHOTOVOLTAIC POWER MODULES

Please read this manual carefully before installing the modules.

KYOCERA

6C-204253

1. INTRODUCTION

As the world leader in development and application of high technology
ceramic/silica materials, Kyocera offers a wide range of highly efficient
and reliable crystalline silicon solar photovoltaic (PV) power modules.
Kyocera began to extensively research PV technology in 1975 and
commenced manufacturing operations in 1978. Since then, Kyocera has
supplied millions of cells and modules throughout the world. With years of
experience and state-of-the-art technology, Kyocera provides the highest
quality PV power modules in a range of sizes designed to meet the
requirements of the most demanding energy and power users worldwide.

2. POWER MODULES

Kyocera power modules consist of a series of electrically interconnected
crystalline silicon solar cells. Which are permanently laminated within a
pottant and encapsulated between a tempered glass cover plate and a
back sheet. The entire laminate is secured within an anodized aluminum
frame for structural strength, ease of installation, and to protect the cells
from the most severe environmental conditions.

3. APPLICATIONS

Kyocera modules are a reliable, virtually maintenance-free direct current
(DC) power source, designed to operate most efficiently in sunlight.
Kyocera modules are ideal to power remote homes, recreational vehicles,
water pumps, telecommunication systems and many other applications
either with or without the use of storage batteries.

4. WARNINGS

Solar modules generate electricity when exposed to light. Arrays of many
modules can cause lethal shock and burn hazards. Only authorized and
trained personnel should have access to these modules. To reduce the
risk of electrical shock or burns, modules may be covered with an opaque
material during installation to avoid shocks or burns. Do not touch live
terminals with bare hands. Use insulated tools for electrical connections.

PERMIT

・ Before installing your solar system, contact local authorities to

determine the necessary permit, installation and inspection
requirements.

INSTALLATION AND OPERATION

・ Systems should be installed by qualified personnel only. The system

involves electricity, and can be dangerous if the personnel are not
familiar with the appropriate safety procedures.

・ Do not step on the module.
・ Although KYOCERA modules are quite rugged, the glass can be

broken (and the module will no longer work properly) if it is dropped
or hit by tools or other objects.

・ Sunlight shall not be concentrated on the module.
・ The module frame is made of anodized aluminum, and therefore

corrosion can occur if the module is subject to a salt water
environment with contact to a rack of another type of
metal.(Electrolysis Corrosion) If required, PVC or stainless steel
washers can be placed between the solar module frame and support
structure to prevent this type of corrosion.

・ The solar module frame must be attached to a support structure

using ¼” or M6 stainless steel hardware in a minimum of four (4)
places symmetrical on the solar module. The stainless steel
hardware used for securing the module frame should secured with
an applied torque of 6 foot-pounds (8 Newton-meters).

・ Module support structures that are to be used to support Kyocera

Solar modules should be wind rated and approved for use by the
appropriate local and civil codes prior to installation.

GROUNDING

・ All module frames and mounting racks must be properly grounded in

accordance with local and national electrical codes.

INSPECTION

・ Follow the requirements of applicable local and national electrical

codes.

BATTERY

・ When solar modules are used to charge batteries, the battery must

be installed in a manner which will protect the performance of the
system and the safety of its users. Follow the battery

manufacturer’s guidelines concerning installation, operation
and maintenance recommendations. In general, the battery (or

battery bank) should be away from the main flow of people and
animal traffic. Select a battery site that is protected from sunlight, rain,
snow, debris, and is well ventilated. Most batteries generate
hydrogen gas when charging, which can be explosive. Do not light
matches or create sparks near the battery bank. When a battery is
installed outdoors, it should be placed in an insulated and ventilated
battery case specifically designed for the purpose.

5. SITE SELECTION

In most applications, KC modules should be installed in a location where
they will receive maximum sunlight throughout the year. In the Northern
Hemisphere, the modules should typically face south, and in the Southern
Hemisphere, the modules should typically face north. Modules facing 30
degrees away from true South (or North) will lose approximately 10 to 15
per cent of their power output. If the module faces 60 degrees away from
true South (or North), the power loss will be 20 to 30 per cent. When
choosing a site, avoid trees, buildings or obstructions which could cast
shadows on the solar modules especially during the winter months when
the arc of the sun is lowest over the horizon.

6. MODULE TILT ANGLE

Kyocera solar modules produce the most power when they are pointed
directly at the sun. For installations where the solar modules are attached
to a permanent structure, the solar modules should be tilted for optimum
winter performance. As a rule, if the system power production is adequate
in the winter, it will be satisfactory during the rest of the year. The module
tilt angle is measured between the solar modules and the ground (Figure

1). Refer to Table 1 for the recommended module tilt angle at your site.

MODULE

SUNLIGHT

TILT ANGLE

HORIZONTAL

Figure 1. Module Tilt Angle

1

Table 1. Recommended Tilt Angles for Fixed S ystems—Based on
Winter Performance

SITE

LATITUDE IN

DEGREES
0°TO 15
15°TO 25°
25°TO 30°
30°TO 35°
35°TO 40°
40°+

FIXED TILT ANGLE

15°

SAME AS LATITUDE

LATITUDE + 5°
LATITUDE + 10°
LATITUDE + 15°
LATITUDE + 20°

7. INSTALLING KC MODULES

The minimum spacing of 0.6 in. (15 mm) is required between the solar
module and the mounting surface around the perimeter of the solar
module. The frame of each module has 0.28”φ diameter (7 mm) mounting
holes (Refer to Module Mounting Specifications). These are used to
secure the modules to the supporting structure. An example of a ground
mounted structure is shown in Figure 2. The four holes close to the corners
of the module are most often used for attachment. Refer to the Mounting
Specification Specifications for the position of these holes. Clearance
between the module frame and the mounting surface may be required to
prevent the junction box from touching the surface, and to circulate cooling
air around the back of the module. If the modules are to be installed on the
roof or wall of a building, the standoff method or the rack method is
recommended.

STAND-OFF METHOD: The modules are supported parallel to the
surface of the building wall or roof. Clearance between the module frames
and surface of the wall or roof is required to prevent wiring damage and to
allow air to circulate behind the module.
The recommended stand-off height is 4.5 in. (about 115 mm) If other
mounting means are employed, this may affect the Listing For Fire Class
Ratings.

RACK: The supporting frame is used to mount modules at correct tilt
angles. The modules are not designed for integral mounting as part of a
roof or wall. The mounting design may have an impact on the fire
resistance.

SUPPORT

LEGS

MOUNTING HOLE

FOOT ANGLE

ARRAY FRAME

MODULE

Figure 2. Basic Rack or Standoff Mounting Structure

8. MODULE WIRING

As shown in Module Mounting Specifications, all of the KC modules utilize
the Type G junction box except the KC85T, KC85TS, KC125TM,
KC130TM modules which utilize the Type M junction box (see J-box
details). This junction box, located on the back side of the module, is
weatherproof and is designed to be used with standard wiring or conduit
connections. Kyocera recommends that all wiring and electrical
connections comply with the 2002 National Electrical Code (NEC). A cable
clamp with a minimum rating of IP65 must be used to maintain the
weatherproof integrity of the junction box.Bypass diodes are preinstalled
at factory

Figure 3. Standard Wiring Examples

To wire Kyocera modules:
A Determine the nominal system array voltage of your system. Each

panel is equivalent to a 12 VDC nominal block. Standard array

voltages 12, 24 and 48 volt are shown as examples in Figure 3.
B. Open the "G" or "M" box cover by loosening the screws in the cover.
C. The wire used to interconnect the solar modules may be single or two

conductors, from 14 AWG (2.08 mm

2

) up to 10 AWG (5.26 mm2)
gauge stranded copper wire, in a “SUNLIGHT RESISTANT” jacket
UF cable. This cable is suitable for applications where wiring is
exposed to the direct rays of the sun. The maximum and minimum
outer diameters of the cable that may be used with the cable
connector are 8 mm and 6 mm respectively (Figure 4).

D. Using a flat blade screwdriver, remove only the appropriate

"KNOCK-OUTS" from the sides of the "G" or "M" box.

E. Route wires through the knock-outs and clamps refer to installation

example (see Figure 5).

F.  Gently hand tighten the terminal screws with cross tip (Phillips head)

screwdriver. Do not over tighten, as the terminal can be damaged.

(Recommendation Torque : 6 foot-pounds (1.5 Newton-meters))
G. The output wiring from the final module is generally run to a separate

array junction box. In commercial system, this wiring from the array
box to the next component (i.e. fuse box. or charge regulator, etc.) is
generally run in conduit. The maximum electrical rating of an
acceptable series fuse is 6〜15 amperes.

H. After checking that module wiring is correct, close and secure all the

junction boxes. Use a Phillips head screw driver to secure all screws

on the junction box cover to ensure a waterproof seal.

2